Methods for mounting or removing belts from telescoping conveyor mechanisms that cooperate with packaging systems having clippers

ABSTRACT

Methods for removing a belt from a telescoping conveyor having a plurality of spaced apart idler rollers in communication with the belt include: (a) translating an idler associated with a telescoping conveyor downward from an operative position to a belt removal and/or belt load configuration while one end portion thereof remains attached to the conveyor frame to thereby allow a conveyor belt to at least partially collapse from an operative configuration; and (b) removing the conveyor belt from the telescoping conveyor after the translating step. 
     Methods of mounting a conveyor belt to a telescoping conveyor include: (a) providing a conveyor belt configured to mount to a telescoping conveyor mechanism; (b) pivoting a first idler roller to an operative fixed position; and (c) translating an idler residing below the first idler roller upward and rearward into its respective operative fixed position to thereby mount a telescoping conveyor belt.

RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.11/851,721, filed Sep. 7, 2007 now U.S. Pat. No. 7,650,729, which claimspriority to U.S. Provisional Application Ser. No. 60/824,959, filed Sep.8, 2006, the contents of which are hereby incorporated by reference asif recited in full herein.

FIELD OF THE INVENTION

The present invention relates to apparatus, systems, methods andcomputer program products that apply clips to packages.

BACKGROUND OF THE INVENTION

Conventionally, in the production of consumer goods such as, forexample, meat or other food products, the food is fed (typically pumped)or stuffed into a casing in a manner that allows the casing to fill witha desired amount of the product. As is well-known, the casings can be aslug-type natural or artificial casing that unwinds, advances, stretchesand/or pulls to form the elongate casing over the desired product.Another type of casing is a heat-sealed tubular casing formed by seaminga thin sheet of flexible material, typically elastomeric material,together. U.S. Pat. Nos. 5,085,036 and 5,203,760 describe examples ofautomated substantially continuous-feed devices suitable for formingsheet material or flat roll stock into tubular film casings. Thecontents of these patents are hereby incorporated by reference as ifrecited in full herein.

It is known to use edible collagen film to cover semi-solid sections ofmeat during processing to form a smoked meat product that gives theappearance of a solid meat muscle, such as a boneless ham. One exampleof a known prior art apparatus used to form a smoked meat product is the“TCM2250” pumpable model from Tipper Tie, Inc., located in Apex, N.C.

Clip attachment apparatus or “clippers” are well known to those of skillin the art and include those available from Tipper Tie, Inc., of Apex,N.C., including product numbers Z3214, Z3202, and Z3200. Examples ofclip attachment apparatus and/or packaging apparatus are described inU.S. Pat. Nos. 3,389,533; 3,499,259; 4,683,700; and 5,161,347, thecontents of which are hereby incorporated by reference as if recited infull herein.

A double clipper can concurrently apply two clips to the tails andleading portions of casings or “chubs”. One clip defines the first endportion of the next package or chub and the other defines the trailingor second end portion of the package or chub then being closed. Acutting mechanism, typically incorporated in the clipper, can sever thetwo packages before the enclosed package is removed from the clipperapparatus. U.S. Pat. No. 4,766,713 describes a double clipper apparatusused to apply two clips to a casing covering. U.S. Pat. No. 5,495,701proposes a clipper with a clip attachment mechanism configured toselectively fasten a single clip or two clips simultaneously. U.S. Pat.No. 5,586,424 proposes an apparatus for movement of U-shaped clips alonga rail. The apparatus includes a clip feed for advancing clips on aguide rail and the arm is reciprocally driven by a piston and cylinderarrangement. The contents of each of these patents are herebyincorporated by reference as if recited in full herein.

In the past, telescoping (axially extending and retracting) conveyors,such as that proposed by U.S. Pat. No. 6,932,688, have been used to hold(clipped) packages of pumped product discharged from a stuffing horn tosupport the packages and transfer them downstream of the clipper. Thecontents of this patent are hereby incorporated by reference as ifrecited in full herein. Nonetheless, there remains a need for alternateaxially telescoping conveyor designs.

SUMMARY OF EMBODIMENTS OF THE INVENTION

Embodiments of the present invention provide axially telescoping “takeaway” conveyor systems with a stationary discharge end portion andrelated, apparatus, systems, methods and computer program products. Thetelescoping conveyors may operate with pivoting or non-pivotingclippers, such as, for example, stationary-mount clippers and can allowfor adjustable (flexibility in size) stuffed package sizes.

The axially extending conveyors may be configured with a relativelyeasily removable and/or belt loading for ease of cleaning (washdown).The axially extending conveyors can include detachable axially extendingand retracting sidewalls that reside above the conveying surface of thebelt.

Spaced apart external vertical (stationary) housing sidewalls residebelow the conveying surface of the belt and hold a mounting arm thatsupports an idler roller or idler. One of the external housing sidewallscan include a quick connect locking member that can be releasablyattachable to the system mounting frame to allow access to an interiorportion of the conveyor mechanism.

Some embodiments are directed to packaging systems that include: (a) aclipper; (b) a conveyor mechanism in communication with the clipper, theconveyor mechanism comprising an axially telescoping conveyor with abelt defining a conveying surface having a conveying length configuredto reciprocally axially extend and retract; and (c) at least one pair ofupwardly extending product guide sidewalls residing at least partiallyabove the conveying surface of the conveyor belt, the pair of productguide sidewalls slidably attached to each other to axially translatesubstantially in concert with the axially telescoping conveyor betweenan extended and retracted position.

Some embodiments are directed to packaging systems that include: (a) amounting frame holding a telescoping conveyor with a belt; (b) a firstidler roller in communication with the belt; (c) an idler incommunication with the belt residing upstream of and lower than thefirst idler roller; and (d) a substantially horizontal axially extendingslot in a mounting bracket attached to the mounting frame, the slot andidler cooperate to allow for adjustment of tension in the conveyor belt.

Some embodiments are directed to telescoping conveyor systems configuredto cooperate with an automated or semi-automated clipper. The systemsinclude: (a) an axially telescoping conveyor with a belt defining aconveying surface having a conveying length configured to reciprocallyaxially extend and retract; and (b) a first idler roller and an idler,each in communication with the belt, and wherein each of the idlerroller and the idler is configured to pivot or translate from anoperative position to a belt removal and reload position.

In particular embodiments, the system can include a frame holding theconveyor, the frame can have a slot sized and configured to slidablyreceive and hold the first idler roller.

Some embodiments are directed to methods of removing a belt from atelescoping conveyor. The methods include: (a) pivoting an idler rollerassociated with a telescoping conveyor from an operative position to abelt removal and/or belt load configuration to thereby allow a conveyorbelt to at least partially collapse from an operative configuration; and(b) removing the conveyor belt from the telescoping conveyor after thepivoting step.

In particular embodiments, the methods may also or alternatively includetranslating an idler residing below and upstream (toward the clipper) ofan idler roller downward before removing the belt and/or lifting off atleast one pair of releasably detachable cooperating product guidesidewalls from the telescoping conveyor before the removing step.

Other embodiments are directed to methods of mounting a conveyor belt toa telescoping conveyor. The methods include: (a) providing a conveyorbelt configured to mount to a telescoping conveyor mechanism; (b)pivoting a first idler roller to an operative fixed position; and (c)translating an idler residing rearward of the first idler upward andrearward into its respective operative fixed position thereby mounting atelescoping conveyor belt.

In particular embodiments, the methods may also include placing amounting arm holding the idler through an aperture in a verticallyextending housing sidewall and inserting a locking member into themounting arm to lock the idler to the sidewall after the belt is mountedto the conveyor. The translating step may be carried out by pivoting theidler rearward and upward to extend laterally (substantiallyperpendicular to the axial direction) in a substantially horizontalorientation, and the method may include sliding the idler roller axiallyin a slot to adjust the tension in the belt after the pivoting step.

In some embodiments the packaging machine can include a control modulewith a computer program product. The computer program product includes acomputer readable storage medium having computer readable program codeembodied in the medium. The computer-readable program code is configuredto automatically direct the extension and retraction of the conveyor,and components associated with an automated or semi-automated clipper,such as, for example, the movement of the voider(s) and actuation offirst and second actuators to substantially synchronize the movement ofthe first and gate members, so that the open configuration is timed tocoincide with the release of target articles and the closedconfiguration is timed to coincide with the capture of target articlesto define the closed gate clip path for the clipper.

These and other objects and/or aspects of the present invention areexplained in detail in the specification set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a side view of a telescoping conveyor (with housing sidewallsomitted for clarity) according to embodiments of the present inventionshowing a retracted configuration of the conveyor.

FIG. 1B is a side view of the device shown in FIG. 1A illustrating theconveyor in an extended configuration according to embodiments of thepresent invention.

FIG. 1C is a side view of a telescoping conveyor (with housing sidewallsomitted for clarity) according to embodiments of the present invention.

FIG. 1D is an end view of the device shown in FIG. 1C.

FIG. 2A is a side view of the device shown in FIG. 1A with side railsaccording to some embodiments of the present invention.

FIG. 2B is a top view of the device shown in FIG. 2A.

FIG. 2C is a side view of the device shown in FIG. 2A but illustratingthe conveyor and sidewalls in the extended configuration according toembodiments of the present invention.

FIG. 2D is a top view of the device shown in FIG. 2C.

FIG. 2E is a side perspective view of the device shown in FIG. 2A.

FIG. 2F is a side perspective view of the device shown in FIG. 2E butillustrating the conveyor and sidewalls in the extended configurationaccording to embodiments of the present invention.

FIG. 3 is a side perspective view of the device shown in FIG. 1Aillustrating removable product guides that can be used with the deviceaccording to embodiments of the present invention.

FIG. 4 is a side perspective view of the device shown in FIG. 1Aillustrating the product guides and exterior housing walls in positionaccording to embodiments, of the present invention.

FIG. 5 is a side perspective view of the device shown in FIG. 4,illustrating one set of product guides and one housing wall and the beltremoved with certain features disengaged to allow belt removal/loadingaccording to embodiments of the present invention.

FIG. 6A is a side perspective view of a subassembly of a sliding portionof a telescoping conveyor according to embodiments of the presentinvention.

FIG. 6B is a side perspective view of a system with the telescoping in apartially exploded view to illustrate an attachment of the subassemblyshown in FIG. 6A to the translating shaft according to embodiments ofthe present invention.

FIG. 7A is a flow chart of operations that can be used to remove a beltfrom a telescoping or other conveyor type for cleaning, repair,replacement or other operations, according to embodiments of the presentinvention.

FIG. 7B is a flow chart of operations that can be used to load a beltonto a (telescoping) conveyor device according to embodiments of thepresent invention.

FIG. 8 is a discharge end perspective view of a packaging apparatus witha telescoping conveyor according to embodiments of the presentinvention.

FIG. 9 is of a side perspective view of the device shown in FIG. 8 takenlooking downstream toward the discharge end according to embodiments ofthe present invention.

FIG. 10 is a discharge end perspective view of the device shown in FIG.8, illustrating idlers pivoted away from an operative position forloading or unloading the belt according to embodiments of the presentinvention.

FIG. 11 is a side view of the intake end portion of the device shown inFIG. 10, illustrating the belt being loaded onto the apparatus accordingto embodiments of the present invention.

FIG. 12 is a side perspective view of the device shown in FIG. 11, takenlooking downstream, illustrating the belt configuration during a loadingsequence and orientation of idlers/rollers according to embodiments ofthe present invention.

FIG. 13 is a side perspective view of the device shown in FIG. 12illustrating the idler roller being mounted in operative position withthe belt thereover according to embodiments of the present invention.

FIG. 14 is a side view of the device shown in FIG. 13 after the idlerroller is in position and before the adjustable idler is lifted intooperative position according to embodiments of the present invention.

FIGS. 15-17 are views of the device shown in FIG. 10 illustrating asequence of operations that can be used to orient the belt andadjustable idler into operative position according to embodiments of thepresent invention.

FIGS. 18, 19A and 19B are views of the device shown in FIG. 10illustrating a sequence of operations that can be used to orient thebelt and forward idler into operative position according to embodimentsof the present invention.

FIG. 20 is a side perspective of the device shown in FIG. 10illustrating the housing sidewall being placed back onto the deviceafter the belt is loaded according to embodiments of the presentinvention.

FIG. 21 is a side perspective view of an adjustable wheel assemblyconfigured for use with a telescoping conveyor according to embodimentsof the present invention.

FIG. 22A is a top view of the telescoping conveyor according toembodiments of the present invention.

FIG. 22B is a side view of the device shown in FIG. 22A according toembodiments of the present invention.

DETAILED DESCRIPTION

The present invention will now be described more fully hereinafter withreference to the accompanying figures, in which embodiments of theinvention are shown. This invention may, however, be embodied in manydifferent forms and should not be construed as limited to theembodiments set forth herein. Like numbers refer to like elementsthroughout. In the figures, certain layers, components or features maybe exaggerated for clarity, and broken lines illustrate optionalfeatures or operations unless specified otherwise. The description of afeature with respect to one embodiment can be included in anotherembodiment, unless described otherwise. In addition, the sequence ofoperations (or steps) is not limited to the order presented in theclaims unless specifically indicated otherwise. Where used, the terms“attached”, “connected”, “contacting”, “coupling” and the like, can meaneither directly or indirectly, unless stated otherwise. The term“concurrently” means that the operations are carried out substantiallysimultaneously.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this invention belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the relevant art and theapplication and should not be interpreted in an idealized or overlyformal sense unless expressly so defined herein.

In the description of the present invention that follows, certain termsare employed to refer to the positional relationship of certainstructures relative to other structures. As used herein, the term“front” or “forward” and derivatives thereof refer to the general orprimary direction that the filler or product travels in a productionline to form an encased product; this term is intended to be synonymouswith the term “downstream,” which is often used in manufacturing ormaterial flow environments to indicate that certain material travelingor being acted upon is farther along in that process than othermaterial. Conversely, the terms “rearward” and “upstream” andderivatives thereof refer to the directions opposite, respectively, theforward and downstream directions.

The term “conveyor belt” means any substrate or floor type including oneor more of metal, polymer, fabric or other food compatible material. Thebelt may have a closed (continuous) or open (foraminated) conveyingsurface surface. Typically the belt is configured to provide a multi-use(over at least one production week) washable floor suitable for foodproduction purposes (and may be FDA approved). One example of a suitableconveyor belt is a belt comprising urethane T10 with Kevlar cords, whichmay have a scuffed surface, identified as a timing belt available fromGates Mectrol, having a place of business in Salem, N.H., under partnumber 150T10/4370KFDA. The belt may be about 150 mm wide and about 4370mm long.

The term “frame” means a generally skeletal structure used to supportone or more assemblies, modules and/or components. The frame can be afloor mount frame. The term “automated” means that operations can becarried out substantially without manual assistance. The termsemi-automatic means that operator input or assistance may be used, butthat most operations are carried out automatically usingelectromechanical devices, pneumatic actuators, and programmaticallydirected operation and control systems.

The terms “idler” and “idler roller” are used interchangeably herein,and where different members are called idler rather than idler roller,this is for ease of discussion rather than to indicate differentfunctional operation, as the idler and idler rollers can each roll andeach communicates with the conveyor belt.

FIGS. 1A and 1B illustrate a telescoping conveyor system 10 thatprovides a belt 15 with a conveying floor 15 f that has an axiallyextending and retracting length, shown as length “L₁” (the shorterlength) in FIG. 1A and length “L₂” (a longer length) in FIG. 1B. Asshown, the downstreammost end portion 10 d can be stationary, with theupstream portion 10 u being configured to axially reciprocallytranslates to provide the telescoping axial length. The distance theconveyor telescopes can vary, such as, for example, between about 10-30inches, and in some embodiments, may axially extend and retract about 21inches.

As shown in FIGS. 1A and 1B, the system 10 can include a first idlerroller 20, a second idler roller 63, a third idler roller 30 and anidler 40 that cooperate to hold the belt 15 in a desired tension. Thefirst idler roller 20 and the idler 40 can be stationary during thetelescoping movement of the belt 15. The system 10 can also include aforward drive wheel 61, and rearward idler roller 65 (also known as anose roller).

FIGS. 1C and 1D illustrate an alternate conveyor system 10′. In thisembodiment front idler roller 20 is omitted and, as shown, the idlerroller 63 can be positioned below idler 40. Idler rollers 30, 65 cantranslate and/or slide with extension and retraction of the conveyorsurface 15 f. That is, idler rollers 30, 65 can mount to the slidingmechanism of the conveyor 10, 10′ and translate in concert with theconveyor floor 15 f. Drive wheel 61 and idler rollers 40, 63 do nottypically axially extend and can be mounted to be affixed in placeduring operation (as is front roller idler 20, where used). Inparticular embodiments, members 30, 40 and 63 can have about the sameouter diameter, such as, for example, about a 2-inch outer diameter,while idler roller 65 may have a smaller diameter, such as about 39.5mm, and drive wheel 61 may have a bout a 55.45 mm diameter. The drivewheel 61, idler rollers 63, 30, 65 and idler 40 cooperate with the beltto provide the desired belt adjustability, tension, and/orconfiguration. The idler 40 cooperates with the belt 15 and the idlerrollers 63, 65, 30 (and optionally, 20) to take-up or release theconveyor belt 15 to maintain a desired tension, whether the belt 15 isin the extended or retracted conveyor surface length 15 f.

As shown, the idler roller 30 and 65 can reciprocally move forward andrearward (substantially horizontally) in response to actuation of ashaft in communication with an actuation rod to thereby adjust the floorlength 15 f. The idler rollers 30 and 65 can mount to the slidingassembly 10 s (see also FIG. 6A) and slidably advance and retract withthe conveyor floor 15 f. As shown in FIGS. 1A, 1B the device has rails30 r that snugly reside in and slide through substantially rigidelastomeric (such as a rigid polymeric, plastic or hard nylon) guides orbushings 10 c attached to the frame 10 f. The embodiment shown in FIGS.1C and 1D do not illustrate the rails 30 r and bushings 10 c as theyreside inside an angle bracket 10 a associated with the housing/frameand, as such, are not shown in these views.

FIG. 6A illustrates one embodiment of a receiving or front-end slidingsubassembly 10 s that defines the rails 30 r that slide with respect tothe frame 10 f to axially extend and retract the floor 15 f. The slidingsubassembly 10 s can attach to a static rear (discharge end) subassemblyto define the axially extendable/retractable conveyor floor, so that thedischarge end portion of the conveyor does not axially translate.

FIG. 6B illustrates a telescoping conveyor/voider assembly 10 v with thesubassembly 10 s attached to the translation drive of the packagingsystem. In this embodiment, a side-mounting arm 233 is attached to acollar 209 affixed to a hub 211 that is in communication with an axiallyreciprocally translating shaft 205. The hub 211 can also be attached tothe forward voider 210. The mounting arm 233 can extend laterallyoutward to a conveyor height adjustor 234. The shaft 205 is incommunication with the actuation rod and actuator (resides upstream ofthe clipper, not shown) to drive the axial extension and retraction ofthe conveyor (and forward voider 210). A detent pin 235 can be used toattach the conveyor 10 to the height adjuster 234. FIGS. 22A and 22Billustrate that a receiving bore 165 can reside under and proximate thenose roller or idler roller 65. The bore 165 is aligned with a bore inthe conveyor height adjuster 234 and the detent pin 235 can extendthrough both bores.

As shown in FIGS. 2A, 2C and 2E, the system 10 can include first andsecond housing sidewalls 11, 12 (the sidewall 12 is shown FIG. 1A) thatmount to the system frame 10 f and hold the idler rollers 20 (whereused), 30 and idler 40.

The idler roller 30 and the idler 40 can pivot and/or rotate whileremaining attached to one of the housing walls 12 to allow for ease ofremoval and/or loading of the belt 15 as shown, for example, in FIG. 5.As shown in FIGS. 1A-1D, the idler roller 30 can have a mounting armwith an end portion 31 that is releasably held by a respective mountingmember 32 to the system frame 10 f. The mounting member 32 can includean open slot 32 s that allows the idler roller 30 to slide forward andout of the mounting member 32 to thereby pivot (typically downwardand/or forward). The mounting member 32 can mount to rails 30 r. Forboth the embodiments shown in FIGS. 1A and 1C, when slid out of the slot32 s, the idler roller 30 can pivot forward.

Similarly, for the embodiment shown in FIGS. 1A and 1B, the idler roller20 (where used) can include a mounting arm with an end portion 21 thatis releasably held by mounting member 22. As shown, the mounting member22 can itself pivot forward and rearward to hold or release the end 21of the first idler roller 20. Thus, one or both members 20, 30 can bemounted so as to pivot and/or rotate when released from the mountingmember 22, 32.

As will be explained further with respect to FIGS. 16, 17, and 21, theidler 40 can be held by a shaft mounting arm 40 a attached to a bracket42. The bracket 42 can be attached to the frame 10 f with a laterallyextending arm 41 that pivots (as shown for example in FIG. 14). At anaxially spaced apart location, the bracket 42 can also be attached tothe wall 12 of the frame 10 f such as with pin 43. When one side ofmember 41 is detached from the frame wall 11 and pin 43 is pulled fromwall 12, one side of the subassembly is released while still holding theidler 40 allowing the idler 40 to translate relative to the operativeconfiguration. The idler 40 and shaft 40 a translation can be configuredso as to rotate and/or pivot downward and/or forward relative to theother laterally opposing end portion 41 b of the arm 41 that remainsattached to the frame 10 f and/or wall 12.

FIG. 21 illustrates the adjustable wheel subassembly 43, which includesslots 42 s on opposing sides of the bracket 42 that allow the axiallocation of the idler 40 to be adjusted. In this embodiment, as shown,the bracket 42 can include a substantially axially extending slot 42 sthat allows for the idler 40 to move axially to adjust tension in thebelt 15, once the belt 15 is loaded to the conveyor 10. The bracket 42can pivot with the idler 40 to translate as shown in FIG. 5, typicallydownward and forward, to allow for removal of the belt 15 as will bediscussed below.

Referring again to FIGS. 1A-1D, these figures also illustrate that thesystem 10, 10′ may also include a package stop 50 that mounts to frame10 f at user selectable locations. The package stop 50 can be configuredas a “trip roller” that includes a proximity sensor that senses an endportion of a pumped encased product and communicates with the clipper tonotify the clipper it is time to void, then clip. The sensor data canalso be used to regulate the pump. The stop 50 can reside above thefloor 15 f and can be attached at any desired axial location, typicallyto siderail 50 r. The vertical position of the stop can also beadjusted. The system 10 can also include an HMI (Human MachineInterface) control module 75 as is known to those of skill in the art.

FIGS. 2A-2F illustrate the system 10 without the belt 15. FIGS. 2A-2Falso illustrate the system 10 with axially extendable and retractableproduct guides 100 (also described herein as upwardly extendingsidewalls) that reside above the conveyor floor 15 f. FIGS. 2A and 2Billustrate the conveyor system 10 in a retracted configuration and FIGS.2C and 2D illustrate the system 10 in the extended configuration. Asshown, the system 10 includes an upwardly extending sidewall 100 withthe floor 15 f therebetween.

Referring to FIGS. 1C, 2A, 2C, 2E, each product guide 100 can includefirst and second sidewalls (shown as relatively thin planar plates) 101,102 with a sliding member, such as a rod or bar, 103 that can slidethrough a bracket 101 b to axially extend or retract the sidewalls 101,102. As shown, the rearward (in the direction toward the clipper)sidewall 102 can be attached to member 104 that mounts to thetranslating portion of the conveyor 10 to reciprocally translate thefirst sidewall 102 substantially in concert with the floor 15 f. Thesliding member (such as a rod or bar) 103 is shown as mounted on anoutside of the sidewall(s) with the sidewalls 101, 102 closely spaced toslide on the inside surface (closer the actual product or conveyor floor15 f) to inhibit obstruction of the product flow, but other sliding ortranslating configurations may be used. Also, one or more separateactuators may be used to translate the guidewalls 100 (not shown) ratherthan translate the guidewalls using the same actuator(s) as thetelescoping conveyor 10. Also, although shown as having the rearwardguidewall 102 move upstream to extend with the telescoping floor 151,the system can be reversed with the forward guidewall 101 configured toextend relative to the rearward guidewall 102.

As shown in FIGS. 2B, 2D and 2E, at least one of the guides 100 can beconfigured to angle inward, such as by tapering laterally inward alongthe axial direction. This can help direct the product to travel towardthe stop member 50. This may be appropriate for devices that package arelatively wide variety of selectable size packages; the size ofpackages (diameter, length, weight) may be adjusted based on, interalia, pump speed, food type, conveyor speed, casing material, conveyorstroke distance and the like.

FIG. 2F also illustrates that releasable locking members 115, such aspins held to the wall 11 with tethers 118 such as chains can be used toreleasably attach the housing wall 11 to the frame 10 f. The lockingmembers 115 can be tapered pins (tapered from large to small, in thedirection of ground) to facilitate tight retention of the wall 11against the frame 10 f. As shown, the end portions 116 e of threeaxially spaced apart cross members 116 can extend through the wall 11and locking members can be used to align the wall to the frame 10 fand/or releasably lock the wall 11 in position. Although the lockingmembers 115 are shown as straight pins, cotter pins or other lockingmember configurations can be used. The moveable end portion 10 u can beconfigured as the sliding subassembly with all the conveyor slidingmembers integrated as a single subassembly 10 s to be light-weight,which takes less force to move the telescoping floor 15 f and alsoincreases speed, reducing cycle time.

FIG. 3 illustrates that the guidewalls 100 can be detached from thesystem 10. As shown, the guidewalls 100 can include at least onemounting pin 105 (typically two axially spaced apart pins) that can besnugly matably received in a respective bracket 10 b attached to theframe 10 f. Thus, the guidewalls 100 can be slidably lifted off theconveyor system 10. The guidewalls 100 can be configured to beadjustably positioned relative to the conveyor floor 15 f and eachguidewall 100 on a respective side of the floor 15 f can be configuredthe same as the other. Further, each, or only one, end portion of eachside of the guidewalls 100 can be slidably mounted to the frame 10 f soas to be able to be moved transversely in or out to adjust for differentsize products as desired.

FIG. 3 also illustrates that the conveyor system 10 can be used with aclipper 200 residing downstream thereof, proximate the receiving end ofthe conveyor system 10. Clippers are well known to those of skill in theart as discussed above. The clipper 200 can include voiders 210 as isalso known to those of skill in the art. As shown in FIGS. 3 and 9, thesystem 10 includes a shaft 205 in communication with an actuator/rod(which may reside upstream of the horn and is typically pneumatic) thatautomatedly drives the reciprocal translation of the conveyor. Asdiscussed above with respect to FIG. 22B, as shown in FIG. 9, at leastthe downstream-most voider 210 may also be in communication with theshaft 205 to axially translate substantially in concert with theconveyor 10. FIGS. 8, 9 and 11 illustrate other views of the clipper 200and a horn 300 that pumps flowable meat emulsions for packaging that maybe particularly suitable for use with the telescoping conveyor 10.

FIG. 4 illustrates exemplary steps that can be used to release the belt15 from the conveyor 10 for cleaning (or repair or replacement). Asshown, at least one of the product guide(s) 100 can be lifted off thesystem 10 (typically only one is removed). Then, the retaining pins 115are pulled from the apertures in the end portions 116 e of laterallyextending members 116. (These steps can be reversed or carried outsubstantially concurrently). Next, the side panel or sidewall 11 can beremoved. The idler 40 can then be translated (typically pivoted orrotated) down to loosen the belt 15. Next, when the embodiment shown isused, the forward idler 20 can be unlatched from holder 22 and the idlerroller 20 can drop or be moved down to release the belt 15. This step isomitted for the embodiment shown in FIGS. 1C and 1D. The rearward idlerroller 30 can be rotated and/or pivoted (typically forward). The forwardidler roller 20 and rearward idler roller 30 can be moved earlier in thebelt releasing steps than that noted in this exemplary process.

FIG. 5 illustrates the conveyor system 10 with the product guide 100removed and the idler rollers 20, 30, 63, 65 and idler 40 held to theframe 10 f (directly or indirectly) with members 20, 30, 40 translatedfrom the operative configurations in a belt release and reloadconfiguration. For the embodiment shown in FIGS. 1B and 1C, theconfiguration for load/release is similar to that shown in FIG. 5, butwith the omission of member 20 and mounting member 22.

FIG. 7A illustrates a flow chart of operations for methods that can beused to remove a belt from a telescoping conveyor. As shown, at leastone, typically at least two, spaced apart rollers (idler or idlerrollers) associated with a telescoping conveyor can be pivoted and/orrotated from an operative position to a belt removal or loadconfiguration to thereby allow a conveyor belt to at least partiallycollapse from an operative configuration (block 400). The conveyor beltcan be removed from the telescoping conveyor after the pivoting step(block 405).

In some embodiments, the method may also include lifting off at leastone pair of cooperating product guides from the telescoping conveyor(block 402). The pivoting/rotating (i.e., translating) step can includepivoting the idler residing below one of the idler rollers downwardbefore removing the belt, either before, during or after pivoting theidler roller (block 403). Optionally, before pivoting the idler, themethod can include removing at least one housing sidewall which holdsthe idler to the conveyor frame, then pivoting the idler downward andforward while one end thereof is held by an opposing sidewall (block404).

FIG. 7B illustrates operations that can be used in methods to load abelt to a telescoping conveyor. As shown, a conveyor belt configured tomount to a telescoping conveyor mechanism is provided (block 420). Theconveyor belt is placed over a conveyor belt support surface andallowing the belt to drape down therefrom (block 422). The belt isoriented to extend over an upstream end portion of the conveyormechanism (block 424). The belt is guided over an outer surface of anidler roller, then the idler roller can be translated (typicallypivoted) into its respective operative fixed position (block 428). Anidler residing upstream of the idler roller is translated to anoperative fixed position, thereby pushing a portion of the belt residingunder a conveying surface of the belt rearward in response thereto tohold the conveyor belt in an operative configuration (block 430).

Optionally, a lower region of the upstream end portion of the belt isplaced over an upper portion of a first idler roller, then the idlerroller is rotated to an operative fixed position and latched in position(block 426).

The belt loading method may optionally also include guiding a mountingarm holding the idler rearward and upward and attaching a pin to amounting bracket held by a vertical housing sidewall to lock the idlerto the sidewall (block 435). Also, the method may include sliding theidler axially in a slot to adjust the tension in the belt (block 432).

FIG. 8 is an end perspective view of a conveyor system 10 with the belt15 in place and the other components in an operative configuration. Asshown, the system 10 is aligned with a packaging apparatus with aclipper 200, voider 210 and horn 300 (shown rotated out of axialalignment). Generally stated, when the clipper 200 can include a clippath that directs a string of clips along a (curvilinear) rail to a clipwindow. As is well known, a punch can automatically force a forwardmostclip down the clip window and into the clip gate to cooperate with alower forming die to wrap the (at least one) clip around a trailing orleading gathered edge portion of a product package to close or seal thepackage. Generally stated, the clips are applied to the gatheredpackaging material to deform to wrap around and close or seal theproduct therein. The clip(s) can be tightly pressed to form a sealagainst the casing that can be sufficiently strong so as to be able tohold a vacuum of about 16 mm Hg for about 24-48 hours. Examples ofsuitable clips include metallic generally “U”-shaped clips availablefrom Tipper Tie, Inc., in Apex, N.C. Other clips, including elastomericclips or other clip materials and clip configurations may also be used.

FIG. 9 is a side perspective view of the system 10 with a portion of theclipper 200 illustrating the voider plates 210 with at least one forwardvoider plate attached to a shaft 205 with a hub 211 that translates thereceiving end portion of the conveyor 10.

FIG. 10 illustrates an exemplary ready-to-load belt configuration of thetelescoping conveyor system 10. As shown, the outer product guide 100 isremoved and the first and second idler rollers 20, 30 and the idler 40are all pivoted out of their operative configuration but each is held tothe system frame 10 f by a respective one end portion of a laterallyextending mounting arm 21, 31, 41 (directly or indirectly).

The belt 15 is loosely draped over the frame 10 f and may be held by thebracket 10 b that holds the guide 100. FIGS. 11 and 12 illustratepreliminary belt loading steps that can be used to position the belt.FIGS. 13-17 illustrate belt placement using the idler roller 30 andidler 40. FIGS. 18-20 illustrate belt placement using the idler roller20. The steps shown in FIGS. 18, 19A and 19B may be carried out beforethose shown in FIGS. 13-17. As noted above, with respect to theembodiment shown in FIGS. 1C and 1D, the loading steps are similar withthe omission of roller 20 and the associated steps.

FIG. 16 illustrates that the idler 40 can be pivoted rearward via alaterally extending pivot arm 41 that has a first end 41 a pivotablyattached to the frame 10 f (typically to sidewall 12). The other end 41b mounts to (typically extends through) the other sidewall 11. The idler40 pivots upward so that bracket 42 aligns with mounting channel 44 tohelp hold the idler 40 in position as shown in FIG. 17. A locking pin 43can be used to lock the idler bracket to the wall 12. A similarconfiguration may be used to hold the other portion of the idler bracket42 to the other wall 11.

The packaging system can pump product through a horn 300 and encases theproduct in casing material as it exits the horn 300. In operation, theencased product can be fed to the voiding/clipping apparatus 200/210that can be configured to produce a series of single products or aseries of chained encased products using either of the two types ofcasings. A clip is applied to the beginning portion of a casing, food ispumped into the casing, and the filled casing is moved downstream fromthe filling point adjacent the discharge end of the horn. The fillingcan be interrupted momentarily while excess product is voided (pushedaway from a clip zone on the package) and one clip can be applied (ortwo clips can be applied concurrently) to the package and/or casing atproximate but spaced apart lateral locations in the clip zone.

The clippers 200 of the instant invention can be operated to manually,semi-automatically or automatically apply closure clips to seal or holdproducts held in the casings and/or netting. Examples of exemplarydevices and apparatus used to void, clip, package and/or tension casingmaterial are described in U.S. Pat. Nos. 5,085,036, 5,203,760,4,847,953; 4,675,945; 5,074,386; 5,167,567; and 6,401,885, and U.S.Patent Application Publication No. US-2005-0039419-A1, the contents ofwhich are hereby incorporated by reference as if recited in full herein.

The target products for packaging may be a linked chain of elongatedextruded product held in a casing or discrete objects held in netting orother materials. The casing can be any suitable casing (edible orinedible, natural or synthetic) such as, but not limited to, collagen,cellulose, plastic, elastomeric and/or polymeric casing.

The encased product can be a food product, such as a meat product.Exemplary meat products include, but are not limited to, strands of meat(that may comprise pepperoni, poultry, and/or beef or other desiredmeat), and processed meat products including whole or partial meatmixtures, including sausages, hot dogs, and the like. Other embodimentsof the present invention may be directed to seal other types of food(such as cheese) or other product in casing materials or enclose theproduct in packaging material. Examples of other products that can besealed in casing material include powders such as granular materialsincluding grain, sugar, sand and the like or other flowable materialsincluding wet (similar to that held conventionally in cans) pet food orother powder, granular, solid, semi-solid or gelatinous materials.Examples of products that can be packaged in netting or other materialsalso include non-pumpable items, such as, for example, bone-in orboneless hams (half, whole or other size), fresh, frozen or previouslyfrozen turkeys (whole), and other discrete objects. The product may bepackaged for any suitable industry including food, aquaculture,agriculture, environmental, chemical, explosives, or other applications.

While described with respect to a certain type of operation, telescopingconveyors and clippers of the instant invention are not limited theretoas they may be used with many different types of equipment (withnon-pumpable product and chutes, with netting, without netting, withstandard casings rather than heat-seal casings, and the like). In someembodiments, in operation, during the pumping process, the casing isdrawn off the product horn, stuffed with product, and concurrentlyencased in (elastic) netting. The moisture and/or exudates(s) in theproduct can cause the casing to cling to the product and seal theoverlapping layers of the casing together along a lower lap seal.

Typically the downstream end portion of the netting and casing isclipped or closed to capture the discharged product therein. As theproduct is discharged from the horn 300 it expands the casing andnetting to create a package shape. The netting is stretched tightly overthe product with the casing therebetween. The netting can hold thepackage together during the cooking or other subsequent process and canprovide a uniform, aesthetically appealing crosshatch pattern on thefinished product.

The size of the package formed can vary depending on the casing size,the length of time the filler is activated to discharge product, thetension of the netting, and/or the conveyor speed of the conveyorreceiving and holding the encased product. Once the package is filled,the voider 210 can void a target portion of the package and the clipper200 can apply one or more clips to the voided region of the package.Typically two clips are applied and the package is severed between theclips using an automatically actuated knife, as is well known to thoseof skill in the art. However, a series of linked products can be formed(such as a product known as “beer balls”) where a single clip is placedbetween the linked products and two clips can be applied to stop thelinked package and start another series.

The packaging system can be configured to mount other horns and rundifferent casing types, such as a heat seal horn and a shirred casinghorn. Thus, the apparatus can be a multi-modal device that accepts atleast two different horns, each operating using a common Human MachineInterface, such as, for example, the HMI 75 (FIG. 1) or a primary HMIdisposed upstream thereof and clipper/voider 200/210 assembly to allowmore manufacturing adaptivity. A horn that may be configured to providecasings can be one that processes a slug-type natural or artificialcasing that unwinds, advances, stretches and/or pulls to form theelongate casing over the desired product. Another type of casing is aheat-sealed tubular elastomeric casing formed by seaming a thin sheet offlexible material, typically polymeric material, together. Examples oftubular casing forming apparatus and an associated heat-sealing horn aredescribed in U.S. Pat. Nos. 5,085,036 and 5,203,760, the contents ofwhich are hereby incorporated by reference. However, as stated above,the apparatus may be a non-pumpable apparatus or may be configured toproduce the tubular casings using additional and/or alternative joiningor seaming means.

FIGS. 22A and 22B illustrate a conveyor/voider assembly 10 v. Theassembly 10 v can include a linear actuator 387 that connects to member388 that rotates shaft 389. The shaft 389 is attached to two pair ofyokes and eccentrics 390 that cooperate to close and open opposing sidesof the respective voiders 210 to void then separate responsive toactuation of the actuator driving the rotation of the shaft 389. Thus,in some embodiments, the packaging system can include a voider assembly10 v that is aligned with the conveyor 10. The voider assembly 10 v caninclude a linear actuator 387 attached to shaft 389, and a first andsecond pair of axially spaced apart yokes 390 attached to the shaft 389.In operation, the linear actuator moves laterally inward and outward torotate the shaft 389 to automatically force pairs of voider plates 210to travel laterally toward each other, then away from each other. Asshown, the voider plates 210 comprise a first downstream voider platepair and a second upstream voider plate pair. The shaft 389 can beattached to the first voider plate pair that axially translates thefirst voider plate pair in concert with the telescoping conveyor 10. Theshaft 389 can also include collar 209 adjacent the hub 211, whichaxially translates the telescoping conveyor 10.

The flowcharts and block diagrams of certain of the figures hereinillustrate the architecture, functionality, and operation of possibleimplementations of embodiments according to the present invention. Itshould also be noted that in some alternative implementations, thefunctions noted in the blocks may occur out of the order noted in thefigures. For example, two blocks shown in succession may in fact beexecuted substantially concurrently or the blocks may sometimes beexecuted in the reverse order, depending upon the functionalityinvolved.

The foregoing is illustrative of the present invention and is not to beconstrued as limiting thereof. Although a few exemplary embodiments ofthis invention have been described, those skilled in the art willreadily appreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. Accordingly, all such modifications areintended to be included within the scope of this invention as defined inthe claims. In the claims, means-plus-function clauses, where used, areintended to cover the structures described herein as performing therecited function and not only structural equivalents but also equivalentstructures. Therefore, it is to be understood that the foregoing isillustrative of the present invention and is not to be construed aslimited to the specific embodiments disclosed, and that modifications tothe disclosed embodiments, as well as other embodiments, are intended tobe included within the scope of the appended claims. The invention isdefined by the following claims, with equivalents of the claims to beincluded therein.

1. A method of removing a belt from a telescoping conveyor incommunication with a clipper, comprising: pivoting an idler residingunder a conveying surface of the conveyor belt between forward andrearward idler rollers downward from an operative position to a beltremoval configuration while one end portion thereof remains attached toa conveyor frame to thereby allow a conveyor belt to at least partiallycollapse from an operative configuration, wherein the idler is mountedto the conveyor frame with a mounting bracket having a substantiallyhorizontally extending slot and does not move axially with thetelescoping conveyor belt during operation, and wherein the pivotingstep is carried so that the slot is substantially horizontal in theoperative configuration and substantially vertical when pivoted downwardto the belt removal configuration; and removing the conveyor belt fromthe telescoping conveyor after the pivoting step.
 2. A method accordingto claim 1, further comprising pivoting a first idler roller residingabove and downstream of the idler and pivoting a second idler rollerresiding above the idler and under the belt conveyor surface beforeremoving the belt.
 3. A method according to claim 2, further comprising,before pivoting the first idler roller and the idler, removing at leastone downwardly extending housing sidewall off one transversely extendingsupport bar, wherein the housing sidewall holds the idler in place onthe conveyor during operation, then translating the idler downward andforward while the one end held by the conveyor frame is held by anopposing downwardly extending housing sidewall.
 4. A method according toclaim 3, further comprising lifting off at least one pair of releasablydetachable cooperating product guide sidewalls from the telescopingconveyor before the removing step.
 5. A method according to claim 1,wherein the idler has first and second transversely spaced apart endportions, each attached to respective one of first and secondtransversely spaced apart downwardly extending housing sidewalls duringoperation, wherein the end portion of the idler that remains attached tothe conveyor frame during the pivoting step is attached to the firstdownwardly extending housing sidewall, the method further comprising,before pivoting the idler, removing the second downwardly extendinghousing sidewall off a transversely extending support bar that has a tipportion that extends beyond the second housing sidewall when the secondhousing sidewall is attached thereto.
 6. A method according to claim 1,further comprising, before the pivoting step, removing at least one pairof upwardly extending product guide sidewalls residing at leastpartially above the conveying surface of the conveyor belt, the at leastone pair of product guide sidewalls being slidably attached to eachother to axially translate substantially in concert with the axiallytelescoping conveyor between an extended and retracted position.